Porous material for insertion cleaning of instruments

ABSTRACT

A porous material for insertion cleaning of instruments is provided, such porous material including an at least partially open-cell foam body and a surface configured to enable an instrument having contaminants to be inserted into the body. The body may be configured to substantially grip the instrument to remove a substantial portion of the contaminants from the instrument.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/562,110 filed Jul. 30, 2012, issued as U.S. Pat. No. 8,635,735 onJan. 28, 2014, which is a continuation of U.S. patent application Ser.No. 10/350,640 issued as U.S. Pat. No. 8,231,734 on Jul. 31, 2012, whichclaims priority to U.S. Provisional Patent Application Ser. No.60/417,802 filed Oct. 10, 2002, the disclosures of which are herebyincorporated by reference in their entireties.

BACKGROUND AND SUMMARY

Various industries may use different types of instruments. In someindustries, the instruments may need to be maintained in a substantiallyclean state during use. However, use of the instruments may expose theinstruments to different types of contaminants, includingbiocontaminants, dust, dirt, grime, etc. It may be desired to quicklyand effectively reduce the level of contaminants on the instrumentsprior to, during or after use. For example, in the medical and/or dentalfields, instruments may need to be cleaned prior, during and aftermedical and/or dental procedures.

As an example, dental instruments may require periodic servicing duringa dental maintenance and/or treatment procedure, such as an endodonticprocedure. In an endodontic procedure, dentists must have ready accessto instruments, such as endodontic files. The endodontic files may beused to gauge the depth of root canals prepared in a patient's teeth.Typically, a dental assistant is employed to hold a file dispenser fromwhich the dentist can withdraw sterile endodontic files.

During the endodontic procedure, the endodontic files may collect pulpaltissue, dentin shavings and/or various medicaments. To clean suchmaterials from the endodontic files, a dental assistant may be requiredto wipe the instruments with a gauze sponge. Wiping the instrument withsuch a sponge may be inadequate to clean the instruments and may becumbersome for the dental assistant.

SUMMARY

A porous material for insertion cleaning of instruments is provided,such porous material including an at least partially open-cell foam bodyand a surface configured to enable an instrument having contaminants tobe inserted into the body. The body may be configured to substantiallygrip the instrument to remove a substantial portion of the contaminantsfrom the instrument.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a dental instrument servicing systemincluding a cushion constructed of a porous material according to anembodiment of the present invention.

FIG. 2 is a rear view of the dental instrument servicing system shown inFIG. 1 including a lowered back wall forming an enlarged instrumentdocking area.

FIG. 3 is a cross-sectional side view of the dental instrument servicingsystem of FIG. 1 taken generally along line 3-3 of FIG. 1.

FIG. 4 is a schematic illustration of some of the characteristics of theporous material of FIG. 1.

FIG. 5 is a schematic illustration of the use of the porous materialshown in FIG. 3 to insertion clean an instrument.

DETAILED DESCRIPTION

As disclosed herein, a porous material is provided that enablesinsertion cleaning of instruments. The porous material may be used toclean instruments from a variety of industries, including, but notlimited to, high-technology industries, medical industries, dentalindustries, etc. Although the following description illustrates the useof a porous material in a dental instrument servicing system, it shouldbe appreciated that a similar porous material may be used in other typesof medical, dental and high-technology instrument cleaning systems.

For illustration purposes, the porous material may be mounted in suchdental instrument servicing systems described and disclosed in thefollowing patents: U.S. Pat. No. 4,280,808 to Johnsen and Oien entitled“Endodontic File Holder” issued Jul. 28, 1981; U.S. Pat. No. 5,368,482to Johnsen and Oien entitled “Dental Instrument Servicing System” issuedNov. 29, 1994; and U.S. Pat. No. 6,036,490 to Johnsen and Oien entitled“Dental Instrument Servicing System” issued Mar. 14, 2000, thedisclosures of which are hereby incorporated by reference. Althoughdescribed in the context of a dental instrument servicing system, itshould be appreciated that the porous material described below may beused alone or in other types of servicing systems.

An exemplary dental instrument servicing system 10 is shown generally inFIG. 1. As shown, system 10 may include a socket-forming member 12,which in turn may carry an insert or cushion 14. The system may furtheroptionally include a medicament holder 16 and a finger mount 18. Thecushion, medicament holder and finger mount may be selectively removablefrom the socket-forming member.

Socket-forming member 12 may define a double-open-ended socket 20, whichprovides a seat for cushion 14. Although not required, thesocket-defining member may be of unitary construction, being formed of alightweight material such as plastic or aluminum. These materials, itwill be appreciated, typically are inexpensive, may be formed by moldingprocesses, and may be suitable for hand-worn use.

Socket-forming member 12 may include plural walls that define socket 20.For example, socket 20 may be defined by front wall 22, side walls 24,26 and back wall 28 (shown in FIG. 2). Typically, the cushions aresomewhat abrasive such that the abrasiveness of the cushion providesfrictional adherence of the cushion to the walls of the socket-formingmember. In some embodiments, cushion 14 may be removably inserted intosocket 20 and retained by one or more of the walls of socket formingmember 12. Additionally, in some embodiments, projections (shown in FIG.3 at 30) may extend outward from side walls 24, 26 and may providefrictional anchors, which may help to maintain cushion 14 within socket20.

As illustrated, cushion 14 may be generally pie-shaped such that itconforms closely to the shape of the socket. However, it should beappreciated that cushion 14 may be any suitable shape depending on thesystem.

The upper end of socket-forming member 12 may be of a predeterminedcontour. For example, the socket-forming member may define a pluralityof distinct regions, each of which may accommodate different servicingoperations. The distinct regions may face in different angulardirections.

Cushion 14 may include a plurality of distinct cushion surface regions14 a, 14 b and 14 c. These cushion surface regions may substantiallymimic the contour of the upper end of the socket-forming member 12. Eachcushion surface region may be adapted to receive files of apredetermined size and/or style. Therefore, the system may be used toorganize endodontic files, or other instruments, by placement ofselected files into predetermined cushion surface regions.

In FIG. 1, for example, file 32 is placed in right-most region 14 a,whereas file 34 is in central region 14 b. It should be noted that thecushion surface regions may include a substantially planar surface (asshown in reference to 14 a and 14 b) or may be contoured. Contouredsurfaces may provide additional surface area for organizing and placinginstruments. For example, cushion surface region 14 c undulatesproviding additional distinct regions for placing instruments.

Finger mount 18 also may be attached to socket-forming member 12. Fingermount 18 may allow the system to be positioned on an individual'sforefinger for use during a dental procedure. The finger mount may beremovably attached to socket-forming member 12 via a cooperative slidearrangement, as described in previously issued U.S. Pat. No. 4,280,808,which has been incorporated by reference above. Typically, such a systemis relatively lightweight and is not appreciably more burdensome than alarge ring. Thus, such a system typically will not significantlyinterfere with use of the wearer's hand.

Socket-forming member 12 also may include an outwardly projecting shelf36. The shelf may extend outward covering finger mount 18 and mayprotect a user's finger from injury by sharp instruments, such asendodontic files, which may be inserted into the cushion. The shelf mayfurther serve as a measuring device for use in connection withendodontic files. Thus, shelf 36 may include a trough 38 for receipt ofendodontic files. A scale 40 may be etched into shelf 36, accommodatingaccurate positioning of depth markers on the file. The use of such ameasuring device is more fully described in the aforementioned U.S. Pat.No. 4,280,808, which has been incorporated herein by reference above.

As briefly described above, medicament holder 16 may be removablyapplied to socket-forming member 12. Medicament holder 16 may include acup section configured to hold a medicament in a dosage container and aclip section (not shown) configured to selectively attach the medicamentholder to the socket-forming member.

Referring to FIG. 2, socket-forming member 12 further may include aservice platform 42. Service platform 42 may project from back wall 28.The service platform may be adapted for receipt of depth markers 44.Depth markers 44 may be used in connection with endodontic files 32, 34.As indicated, service platform 42 may include one or more recessedopenings 46, 48, each of which may be configured to hold one or moredepth markers 44 for application to endodontic files. A depth marker maybe applied to an endodontic file by insertion of the endodontic filethrough an aperture formed in recessed openings 46, 48.

FIG. 2 also illustrates that back wall 28 may be lowered relative tofront wall 22 to provide for an enlarged docking area 50 for endodonticfiles. The docking area provides for an increased area to place filesand other instruments. Thus, an instrument, such as endodontic file 52,may be inserted substantially perpendicular to the direction that files32 and 34 are shown positioned in cushion 14. Such a docking area mayenable, a dental assistant to perform a safe pick up without causing thedoctor to break his/her visual field while operating under a surgicalmicroscope. Moreover, the presence of the taller front wall 22 mayoperate as a safety shield. Thus, front wall 22 may shield the dentalinstrument servicing system wearer, such as the dental assistant, fromendodontic files that are inserted into docking area 50 of cushion 14.

FIG. 3 further illustrates cushion 14. As described in more detailbelow, cushion 14 is formed of a porous material, such as foam, suitablefor use in holding and cleaning instruments, such as endodontic files.Tests have been conducted to determine the suitable composition forcushion 14. Exemplary foams are described in TABLE 1 below:

TABLE 1 Foam Foam A Foam B Density (kg/m³) 25.6 ± 2 kg/m³ 22.4 ± 2 kg/m³(kilograms per cubic meter) Material Urethane Urethane Cell Count(cells/cm) 15-16 cells/cm 15-16 cells/cm (cells per centimeter) Air Flow(dm³/sec) 4.1 dm³/sec 3.8 dm³/sec (cubic decimeters per second) 25% IFD(N) 94.7 N 99.08 N (Newtons) 50% CFD (N) 2.8 ± 0.2 N 2.7 ± 0.2 N(Newtons) (0.62 ± 0.05 psi) (0.60 ± 0.05 psi)

It should be appreciated that although two exemplary foams are describedin detail, the composition of suitable cushions may vary. For example,suitable foams for use in the present system may have a differentdensity, air flow, indentation force deflection (IFD), compression forcedeflection (CFD), cell count, etc. Foam A and Foam B, as describedabove, are included only for illustrative purposes and are not intendedto include all suitable compositions for cushion 14.

Generally, the foam characteristics may be balanced to achieve asuitable material for use in insertion cleaning of instruments.Selection of one or more of the density, material, and cell count of thefoam may effect a change in the air flow, the indentation forcedeflection, the compression force deflection, or other characteristic ofthe cushion. For example, selection of the appropriate material mayinclude balancing the density and cell count of the foam, such that thefoam functions as desired.

However, it is noted that suitable foams for cushion 14 typically have adensity in the range of 20 kg/m³ to 30 kg/m³. For example, and as shownabove, Foam A has a density of 25.6±2 kg/m³ and Foam B has a density of22.4±2 kg/m³. Foams that are too dense may inhibit easy insertion andremoval of instruments into the cushion. Likewise, and as described inmore detail below, foams that are not dense enough, may not properlyclean instruments when they are inserted into and removed from thecushion.

In some embodiments, the cushion may be composed of polyurethane.Polyurethane cushions may be able to withstand steam autoclaving withoutsubstantially deforming, melting, or producing any noxious out-gassingof toxic substances during the steam autoclaving process. Moreover,polyurethane is widely and safely used in many medical and dentalapplications.

As briefly noted above, in some embodiments, it may be desirable tosterilize the cushions (and the instruments) prior to use. For example,in many environments, steam autoclaving may be used to sterilize thecushions. Thus, the cushions may be configured to withstandsterilization via steam autoclaving prior to use. Due to the use of thecushions in medical and dental applications, the cushions typically maybe configured to withstand steam autoclaving as performed in clinicalenvironments, where the steam autoclaves typically operate within arange of between 275 degrees and 300 degrees Fahrenheit and a range ofbetween 20 psi and 30 psi.

As shown in FIG. 4, the cushions may include an at least partiallyopen-cell foam body. The at least partially open-cell body may allowsteam from an autoclave to penetrate an interior region 56 of thecushion. Penetration of the interior region enables steam to surroundand effectively sterilize endodontic files or other instruments at leastpartially disposed within the cushion. Arrows 58, shown in FIG. 4,illustrate passageways through which steam may pass through theopen-cell structure of the cushion to the interior region of thecushion, thereby fully penetrating the cushion with steam from theautoclave. It should be noted that the arrows are intended only forillustrative purposes.

Typically, substantially closed cell structures prevent steam frompassing into the interior region of the cushion. Such closed cellcushions may not provide the necessary sterilization of the instrumentspositioned within the cushion. In contrast, cushions that have an airflow of more than approximately 1.0 dm³/second (as measured according tostandard ASTM D 3574 Air Flow Test G) may be adequate to enablesterilization of endodontic files positioned in the interior region ofthe cushion. Typically, suitable cushions will have an air flow range ofapproximately 1.0 dm³/second to 4.5 dm³/second according to ASTM D 3574Air Flow Test G. Two exemplary cushions are described in TABLE 1 (shownabove), specifically, Foam A has an air flow of 4.1 dm³/second and FoamB has an air flow of 3.8 dm³/second.

As illustrated, cushion 14 typically includes a surface 60 configured toenable an instrument to be inserted into the body of the cushion.Instruments, such as file 34, may puncture surface 60 and be pushed intointerior region 56 of the cushion. Typically, surface 60 is resilient,such that surface 60 is able to recover from the puncture and return toits prior state.

In FIG. 4, an endodontic file 34 is shown being inserted into cushion14. The tip of file 34 thus may be seen to penetrate surface 60 andslide through the body into the interior region. The foam may beconfigured to enable such files, or other instruments, of varying shaftdiameters and lengths, to easily penetrate the cushion. Typically, thecushions are “crisp” or “firm” such that the tip of the instrumenteasily pierces the surface (indicated at 62). Such cushions adequatelyresist collapsing when penetrated by an instrument. Materials thatcollapse, or that resist the penetration of files or other instruments,may frustrate the user and may require additional user attention duringuse.

The “firmness” of the cushions may be measured using the 25% indentationforce deflection (IFD) test according to standard ASTM D 3574 Test B. AnIFD number represents the force required to indent a foam sample by aspecified percentage (e.g. 25%) of its original thickness. Cushions forreceipt of endodontic files typically have a 25% indentation forcedeflection of approximately at least 80.00 N. Generally, the cushionswill have an indentation force deflection range of approximately 80.00 Nto 120.00 N, and typically between 92.00 N to 100.00 N. As shown inTABLE 1 above, suitable foams have a 25% indentation force deflection ofapproximately 94.7 N and 99.08 N.

It further should be noted that the foam within the cushions may bedescribed in relation to their compression force deflection (CFD)values. CFD values may be obtained by determining the force required tocompress an entire sample surface area to 50% of its sample height. Asshown in TABLE 1 above, exemplary Foam A has a CFD value of 2.8±0.2 Nand exemplary Foam B has a CFD value of 2.7±0.2 N. Foams with other CFDvalues may be suitable, providing that the material enables smoothinsertion of instruments into the cushion.

FIG. 5 schematically illustrates the instrument cleaning properties ofthe cushions. Generally, the abrasive action of the foam in a cushionfunctions to substantially clean instruments inserted therein. Morespecifically, the porous material in the cushion is configured to gripan instrument, such as a dental file (indicated generally at 64 in FIG.5), and clean its flutes and ridges, as the instrument is inserted into,and pulled out of, the porous material. The gripping characteristics ofthe porous material substantially decrease contaminants and otherresiduals on the instrument.

For example, as shown in FIG. 5 at 66, during a medical or dentalprocedure, an instrument, such as file 64, may accumulate contaminants,such as bioburdens 68. Bioburdens, such as pulpal tissue, dentinshavings and various medicaments may cling to the file. For example,bioburdens 68 may extend along shaft 70 of file 64. Insertion of file 64into cushion 14 may occur by penetrating surface 60, as indicated byarrow 72.

Insertion of file 64 into cushion 14 results in shaft 70 extending atleast partially into the interior region 56 of cushion 14. Bioburdens68, or other contaminants, may be sloughed off of shaft 70 as it isinserted into the cushion. Specifically, the cells within the cushionare configured to substantially grip the instrument as it is insertedinto and pulled out of the cushion. By gripping the instrument as it ismoved into and out of the cushion, bioburdens 68 may be displaced fromthe instrument to the cushion.

The composition of the cushion will affect the removal of bioburdens andother contaminants from the instrument. Cushions that are moreopen-celled in architecture may be less effective in removingcontaminants from instruments. Typically, cushions composed of foamhaving a cell count in the range of 12 cells/cm to 20 cells/cm have beenfound to be adequate in removing a substantial portion (e.g. over 90%)of contaminants from a contaminated instrument. Specifically, as shownin TABLE 1 above, foams, such as Foam A and B, which have cell counts of15 cells/cm to 16 cells/cm, function to significantly reducecontaminants on an instrument.

Removal of the dental instrument from cushion 14 results in bioburdens68 being left in cushion 14, as shown generally at 76. Specifically,shaft 70 of file 64 is substantially free of bioburdens 68. Furthercleaning of file 64 may include reinsertion of shaft 70 into cushion 14,thereby repeating the steps illustrated generally at 66, 74 and 76 inFIG. 5. Multiple insertions of the dental instrument into the cushionmay function to substantially decrease the level of bioburdens or othercontaminants on file 64.

The cleaning effectiveness of the exemplary cushions is illustrated inTABLE 2 below. Specifically, the cleaning effectiveness was measuredusing biological serial dilution techniques. Accordingly, the level ofbioburdens on the instrument was measured prior to, and after, insertionand removal (also referred to herein as a stab) of the instrument intoand out of the cushion. As shown in TABLE 2 below, an 82.6% sporereduction level (level of bioburdens on the instrument) was achievedafter a first stab of the instrument into Foam A and B. A second stabincreased the spore reduction level to 86.3%. A 96% spore reductionlevel was achieved after three insertions (or stabs) of the instrumentinto Foam A and B.

TABLE 2 Foam Foam A Foam B Spore Reduction: 82.6% 82.6% 1 Stab SporeReduction: 86.3% 86.3% 2 Stabs Spore Reduction: 96.3% 96.3% 3 Stabs

While the present description has been provided with reference to theforegoing embodiments, those skilled in the art will understand thatmany variations may be made therein without departing from the spiritand scope defined in the following claims. The description should beunderstood to include all novel and non-obvious combinations of elementsdescribed herein, and claims may be presented in this or a laterapplication to any novel and non-obvious combination of these elements.The foregoing embodiments are illustrative, and no single feature orelement is essential to all possible combinations that may be claimed inthis or a later application. Where the claims recite “a” or “a first”element or the equivalent thereof, such claims should be understood toinclude incorporation of one or more such elements, neither requiring,nor excluding, two or more such elements.

What is claimed is:
 1. A method of cleaning a dental instrument,comprising: providing a foam having an interior region and a surface,wherein the foam has a density of at least approximately 22 kilogramsper cubic meter; inserting a dental instrument through the surface andinto the interior region, whereby the foam substantially grips thedental instrument; and removing the dental instrument from the foam,whereby bioburdens are removed from the dental instrument after aninsertion of the dental instrument into the foam.
 2. The method of claim1, further comprising reducing at least about eighty percent ofbioburdens on the dental instrument after a single insertion of thedental instrument into the foam.
 3. The method of claim 2, furthercomprising: reducing over eighty percent of bioburdens on the dentalinstrument after two insertions of the dental instrument into the foam,and reducing over ninety percent of bioburdens on the dental instrumentafter three insertions of the dental instrument into the foam, whereinthe foam has a density within a range of 20 kg/m³ to 30 kg/m³.
 4. Themethod of claim 1, further comprising holding the foam in an innercavity of a housing, the foam being configured for placement in theinner cavity of the housing.
 5. The method of claim 4, wherein the foamhas an air flow through the body of at least 1.0 cubic decimeter persecond (dm³/sec).
 6. The method of claim 1, wherein the foam has an airflow through the body of at least approximately 1.0 cubic dm³/sec. 7.The method of claim 1, wherein the foam has an air flow through the bodywithin a range of 1.0 dm³/sec to 4.5 dm³/sec.
 8. A method of cleaning acontaminated dental instrument, comprising: providing a housingincluding spaced wall members that define a socket; providing a porousmaterial with a foam body having an interior region and a surface,wherein the body has a density of at least approximately 22 kilogramsper cubic meter (kg/m³) and an air flow through the body is at least 1.0cubic decimeter per second (dm³/sec), the porous material beingconfigured for placement in the socket of the housing; inserting acontaminated dental instrument through the surface and into the interiorregion, whereby the porous material substantially grips the dentalinstrument; and removing the dental instrument from the porous material,whereby bioburdens are removed from the dental instrument afterinsertion of the dental instrument into the porous material.
 9. Themethod of claim 8, further comprising reducing at least about eightypercent of bioburdens on the dental instrument after a single insertionof the dental instrument into the porous material.
 10. The method ofclaim 8, further comprising: reducing over eighty percent of bioburdenson the dental instrument after two insertions of the dental instrumentinto the porous material, and reducing over ninety percent of bioburdenson the dental instrument after three insertions of the dental instrumentinto the porous material, wherein the porous material has a densitywithin a range of 20 kg/m³ to 30 kg/m³.
 11. A method of cleaning anendodontic file, comprising: providing an at least partially open-cellfoam body having an interior region and a surface, wherein the foam hasa density of at least approximately 22 kilograms per cubic meter, a cellcount of at least 12 cells per centimeter, and an air flow specificationof at least one cubic decimeter per second, inserting an endodontic filepartially covered with bioburdens, through the surface and into theinterior region of the foam body, whereby the foam substantially gripsthe file, and removing the file from the foam, and leaving at least 80%of the bioburdens in the foam separate from the file in a singleremoving step.
 12. The method of claim 11, wherein the density of thefoam body is at least 25 kilograms per cubic meter.
 13. The method ofclaim 11, wherein the cell count of the foam body is at least 15 cellsper centimeter.
 14. A method of cleaning an endodontic file comprising:providing an at least partially open-cell foam body having an interiorregion and a surface, in a socket member configured for use in anendodontic procedure, inserting a dental instrument partially coveredwith bioburdens, through the surface and into the interior region of thefoam body, whereby the foam substantially grips the file, and removingthe file from the foam, wherein the foam body has a density and cellcount selected to permit autoclaving sterilization of a file partiallyinserted in the cell body, and to retain at least 80% of the bioburdensin the foam body separate from the file in a single removing step. 15.The method of claim 14, wherein the density of the foam body is at least20 kilograms per cubic meter.
 16. The method of claim 14, wherein thedensity of the foam body is at least 22 kilograms per cubic meter. 17.The method of claim 14, wherein the cell count of the foam body is atleast 12 cells per centimeter.
 18. The method of claim 14, wherein thecell count of the foam body is at least 15 cells per centimeter.
 19. Themethod of claim 14, wherein the foam body has an air flow specificationof at least 3 decimeters cubed per second.
 20. A method of cleaning anendodontic file comprising: providing an at least partially open-cellfoam body having an interior region and a surface, in a socket memberconfigured for use in an endodontic procedure, inserting a dentalinstrument through the surface and into the interior region of the foambody, whereby the foam substantially grips the file, autoclaving thedental instrument along with the foam body, the foam body having adensity and cell count selected to permit sterilization of the filethrough the cell body structure, withdrawing the file from the foambody, using the file in an endodontic procedure, and accumulatingbioburdens on the file, reinserting the file partially covered withbioburdens, through the surface and into the interior region, wherebythe foam substantially grips the file, and removing the file from thefoam, wherein the density and cell count of the foam body provideretention of at least 80% of the bioburdens in the foam body separatefrom the file in a single removing step.